Infiltrated aluminum preforms

ABSTRACT

A method for the manufacture of a three-dimensional object includes the steps of forming a mixture that contains a binder and a least one of aluminum or a first aluminum-base alloy into a green composite, removing the binder from said green composite forming a porous preform structure and infiltrating the porous structure with a molten second aluminum base alloy to form the three-dimensional object with near theoretical density. The green composite may be formed by an additive process such as computer aided rapid prototyping, for example selective laser sintering. The method facilitates the rapid manufacture of aluminum components by an inexpensive technique that provides high dimensional stability and high density.

CROSS REFERENCE TO RELATED APPLICATION(S)

[0001] Not Applicable U.S. GOVERNMENT RIGHTS

[0002] Not Applicable

BACKGROUND OF THE INVENTION

[0003] 1. Field of the Invention

[0004] This invention relates generally to a method for the rapidmanufacture of aluminum alloy components and can have specificapplication to limited production runs, such as those encountered inrapid prototyping or rapid manufacturing. More particularly it relatesto a method whereby a porous aluminum or aluminum alloy preform isformed into a desired shape and supported by a polymeric binder. Asecond, lower melting temperature, aluminum alloy is caused toinfiltrate the porous preform forming a dense structurally soundcomponent.

[0005] 2. Description of the Related Art

[0006] Aluminum and aluminum alloy components are traditionallyfabricated by casting, mechanical working or machining, as well ascombinations of these processes. When casting, molten metal fills amould having an internal cavity formed into the shape of a desiredcomponent. After the molten metal cools and solidifies, the component isremoved from the mould in either net shape (finished form) or near netshape (close to finished form, but requiring some additional working ormachining). When mechanical working, such as forging, drawing, rolling,extrusion or stamping, a cast billet of the metal is mechanicallydeformed into the shape of the desired component. Casting requiresmoulds machined to the shape of the desired component while tools usedto apply mechanical deformation require dies formed to the requiredshape. While both casting and mechanical working are well suited for theeconomical manufacture of large quantities of identically shapedcomponents, neither is particularly suitable for specialty applicationsor prototypes where only a few components are required or where variousaspects of the shape are to be varied from component to component.

[0007] Aluminum and aluminum alloy components can also be machined fromstock material that may have been mechanically worked or cast. Machiningis time consuming, has a very poor utilization of raw material andrequires skilled operators. Machined components are therefore expensiveand slow to produce.

[0008] Aluminum powders can also be used to fabricate parts, either totake advantage of a unique property set or because net shape parts canbe inexpensively fabricated. In the former case, the powders aretypically consolidated by extrusion, forging or hot isostatic pressing.Net shape parts are made by pressing aluminum powder at extremely highpressures (nominally in excess of 30,000 pounds per square inch) intohard tooling cavities to achieve green densities as high as 95%. Afterpressing, the part is ejected from the die and the so-called green bodyis sintered in a furnace at elevated temperatures under a controlledatmosphere, commonly nitrogen. Aluminum, and aluminum alloys, have apropensity to form a highly stable alumina (Al₂O₃) surface film thatpassivates the individual powder particles limiting further oxidation.The surface oxide also hinders the diffusional mechanisms needed tosinter aluminum powder preforms into fully dense aluminum components. Asa solution to this challenge, the aluminum powder industry has developedblends of aluminum powder, surface oxide reducing agents, lubricants andsintering agents. All of these technologies require tooling or dieswhich are used to shape the part. This tooling is expensive and is timeconsuming to produce. This delays the time needed to introduce newproducts and increases their cost.

[0009] An alternative production strategy produces three-dimensionalobjects directly from the manipulation of data from computer aideddesign (CAD) databases. Various technologies are known to produce suchparts, particularly through the use of additive processes as opposed tosubtractive processes such as conventional machining. Important additiveprocesses for the production of such parts include stereolithography,selective laser sintering, laminated object manufacturing,three-dimensional printing and fused deposition modeling. A commonfeature of all of these rapid prototyping and rapid manufacturingtechniques is that energy and/or material is delivered to a point toproduce a solid. A series of lines are then traced out to make across-sectional layer and a series of layers formed to make a threedimensional part. In principle, there are as many such potentialmanufacturing systems as there are ways to write or draw on a surface.Producing components in this way has a number of important advantagesover traditional manufacturing processes. Most importantly, parts of anyshape can be produced directly from a CAD model without the need forexpensive tooling or machining and these can be produced in a smallfraction of the time that is typically required of traditionalmanufacturing operations.

[0010] Selective laser sintering is described in more detail in U.S.Pat. No. 4,863,538 to Deckard and three-dimensional printing isdescribed in more detail in U.S. Pat. No. 6,416,850 to Bredt, et al.Both the U.S. Pat. No. 4,863,538 and the U.S. Pat. No. 6,416,850 areincorporated by reference in their entireties herein. These techniqueshave been used to fabricate objects made from a variety of materialssuch as photoset resins, other polymers such as nylon and ethylenebutadiene styrene, organic waxes, ceramics such as SiN, and metals, mostcommonly steel.

[0011] Recently, aluminum parts have been produced by selective lasersintering and extrusion freeform fabrication. These aluminum parts werefabricated as polymer/aluminum powder composites and post-processed byburning out the polymer and then sintering the remnant metal powder tofull or near-full density, in a manner similar to that used in powderinjection molding. However, it is extremely difficult to maintaindimensional accuracy during sintering of such a powder preform becauseof density gradients in the green part and geometrical constraints.While uniform shrinkage can be incorporated into the initial CAD design,non-uniform shrinkage, or distortion, is more difficult to controlreproducibly and to accommodate by design. Because dimensional accuracyis a critical criterion for any rapid prototyping/rapid manufacturingsystem, the inability to accurately sinter large parts is fatal. Onlysmall aluminum parts can presently be made this way: the limit isapproximately 1 cm³.

[0012] U.S. Pat. No. 4,828,008 discloses that a permeable ceramic massis spontaneously infiltrated by a molten aluminum alloy containing atleast 1%, by weight, of magnesium and optionally also containingsilicon. “Spontaneous infiltration” means that the molten metalinfiltrates the permeable mass without the requirement for theapplication of pressure or vacuum (whether externally applied orinternally created). U.S. Pat. No. 4,828,008 is incorporated byreference in its entirety herein.

[0013] The dimensional accuracy of a component formed is much improvedby infiltration, whether spontaneous, pressure-assisted orvacuum-assisted. The loosely formed powder body is lightly pre-sinteredand the porous mass is subsequently infiltrated by a liquid metal at atemperature between the melting point of the infiltrant and the basemetal. Because there is so little sintering, there is negligibledimensional change between the preform and the finished part. Numeroussystems have been fabricated by the rapid prototyping/rapidmanufacturing/infiltration route to date, including Fe—Cu, stainlesssteel-bronze, ZrB₂—Cu and SiC—Mg. Aluminum and aluminum base alloys area conspicuous omission from the successful metallic infiltrationsystems. It is theorized that the alumina surface film on the aluminumand aluminum alloy particles may have prevented the infiltration ofporous aluminum components.

[0014] There remains, firstly, a need for a method to spontaneouslyinfiltrate a porous mass of a first aluminum-base material with a moltensecond aluminum-base material. In addition, there remains a need for anadditive process to manufacture aluminum alloy parts that does not havethe above-stated deficiencies. The additive process should result inparts with a density close to the theoretical density of the aluminumalloy and be capable of a high level of dimensional accuracy.

BRIEF SUMMARY OF THE INVENTION

[0015] In accordance with a first embodiment of the invention, there isprovided a method for the spontaneous infiltration of a porousaluminum-base preform. This method includes the steps of forming amixture that contains a binder and at least one of aluminum or a firstaluminum-base alloy into a green composite, removing the binder from thegreen composite forming a porous preform structure, infiltrating theporous preform structure with a molten second aluminum base alloy, toform the three-dimensional object with near theoretical density.

[0016] In accordance with a second embodiment of the invention, there isprovided a method for the manufacture of a three-dimensional object thatincludes the steps of forming a mixture that contains a binder and aleast one of aluminum or a first aluminum-base alloy into a greencomposite, removing the binder from said green composite forming aporous preform structure, infiltrating the porous preform structure witha molten second aluminum base alloy, to form the three-dimensionalobject with near theoretical density. The green composite may be formedby an additive process such as computer aided rapid prototyping, forexample selective laser sintering or a casting or molding process suchas a room temperature vulcanization process like the Keltool® process,metal injection molding, extrusion molding, resin transfer molding,rotational molding, or pressing. The method facilitates the manufactureof aluminum components by an inexpensive technique useful in rapidmanufacturing or rapid prototyping that provides high dimensionalstability and high density.

[0017] For either the first embodiment or the second embodiment, analuminum nitride skeleton may be formed on the surfaces of the aluminumparticles or the particles of a first aluminum-base alloy powder forincreased preform strength and dimensional stability.

[0018] The details of one or more embodiments of the invention are setforth in the accompanying drawings and the description below. Otherfeatures, objects and advantages of the invention will be apparent fromthe description and drawings, and from the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0019]FIG. 1 shows in flow chart representation a process for theinfiltration of a porous aluminum-base preform by a molten aluminum-basealloy.

[0020]FIG. 2. shows in cross-sectional representation an aluminum alloyparticle used to form the porous mass in accordance with an embodimentof the invention.

[0021]FIG. 3 shows in cross-sectional representation a blend of powdersin accordance with an embodiment of the invention.

[0022]FIG. 4 shows in cross-sectional representation the effect ofinitial heating on the blend of powders shown in FIG. 3.

[0023]FIG. 5 shows in cross-sectional representation the effect offurther heating on the blend of powders shown in FIG. 3.

[0024]FIG. 6 shows in cross-sectional representation the effect of stillfurther heating on the blend of powders shown in FIG. 3.

[0025] Like reference numbers and designations in the various drawingsindicated like elements.

DETAILED DESCRIPTION

[0026]FIG. 1 shows in flow chart representation a sequence of processsteps 10 in accordance with a first embodiment of the invention. In afirst step 12, a mixture containing a binder and at least one ofaluminum or a first aluminum-base alloy is formed into a greencomposite. As used herein, “aluminum-base” means that the alloy containsat least 50%, by weight, of aluminum.

[0027] Preferably the mixture comprises a minimum of three powdersblended together. One powder is an aluminum alloy, such as aluminumalloy 6061, that constitutes approximately about 80 to about 95%, byvolume, and more preferably from about 85% to about 90%, by volume, ofthe total mixture. This base metal may be any aluminum-base alloy powderor pure aluminum.

[0028] The aluminum or first aluminum-base alloy is in powder form ofany effective particle size. Preferably the average particle size isbetween about 5 and about 150 microns (1 micron=1 μm=1×10⁻⁶ meter) andmore preferably, the average particle size of the metallic powder is inthe range of from about 10 to about 75 microns. One preferred aluminumalloy is aluminum alloy 6061 that has a nominal composition, by weight,of about 0.4% to about 0.8% silicon, about 0.15% to about 0.40% copper,about 0.8% to about 1.2% magnesium, about 0.04% to about 0.35% chromiumand the balance aluminum and unavoidable impurities.

[0029] As a non-limiting list, the aluminum may be alloyed with one ormore of the following elements copper, magnesium, silicon, zinc,titanium, chromium, zirconium, nickel, iron, manganese and silver.

[0030] A second powder component of the mixture constitutesapproximately about 0.1 to about 4%, by weight, and preferably fromabout 1.5% to about 2.5%, by weight of the total mixture. This secondpowder includes an oxygen-scavenger, such as magnesium that cleans theatmosphere surrounding the mixture and reduces the oxide layer on thealuminum-base metal particles. The oxygen scavenger is in particle formwith an average particle size of between about 5 and about 150 micronsand preferably the average particle size is between about 10 and about75 microns. Other suitable oxygen scavengers include zirconium, lithium,beryllium, calcium, cerium, lanthanum, neodynium, praesodinium,samarium, thorium, uranium, or misch metal.

[0031] As disclosed hereinbelow, while there are benefits to includingthe oxygen scavenger in the powder mixture, effective infiltration isalso obtained if the oxygen scavenger is included in a support layerformed about the green composite, in which case the oxygen scavenger maybe omitted from the powder mixture.

[0032] A third powder component of the mixture, which constitutes about5% to about 15%, by volume, and preferably about 8% to about 12%, byvolume, of the total blend, includes a binder. The binder may be ametallic binder such as zinc stearate, an organic or an inorganicbinder, but preferably is an organic polymeric binder. Organic polymericbinders can include thermoplastics with sharp melting points such asnylon 6, nylon 11, nylon 12, copolymers of nylon 12 and nylon 6,polyacetals, polyethylene, polyethylene copolymers, polymethacrylates,polypropylene, and polyether block amides. The average particle size ofthe polymer binder powder is generally in the range of about 1 to about50 μm. The binder is selected to be a material that decomposes to a gaswith a minimum of carbon residue when heated to a temperature of betweenabout 300° C. and about 500° C. in a suitable atmosphere, such asnitrogen. Where nitrogen is used to create the atmosphere, the nitrogensource can be pure nitrogen, a mixture of gases including nitrogen, anynitrogen rich binder material that evolves nitrogen to form a nitrideskeleton, metal nitrides such as transition metal nitrides or magnesiumnitride.

[0033] The green composite is heated relatively slowly, such as about 1to about 2° C. per minute to facilitate binder vapor outgassing from thegreen composite by way of open, connected, porosity without a build upof localized pockets of vapor pressure that could damage the part.Preferred binders have a relatively low melt flow viscosity (on theorder of 25 to 145 grams per 10 minutes) and substantially completedecomposition to nitrogen, nitrogen compounds and other gases whenheated to a temperature in the 300′-500° C. range. Suitable bindersinclude the aforementioned nylons, and more specifically Orgasol® 2001Nylon-12 (gram molecular weight of 17,400, melt flow viscosity of about25 to about 100 grams per 10 minutes and decomposition temperature ofabout 433 to about 481° C.), Orgasol® 3501 EXD (gram molecular weight of6,500, melt flow viscosity of about 25 to about 100 grams per 10 minutesand decomposition temperature of about 414 to about 472° C.) andOrgasol® 3501UD (melt flow viscosity of about 25 to about 100 grams per10 minutes and decomposition temperature of about 425 to about 472° C.).All of these aforementioned Orgasol® nylon binders are availablecommercially from Atofina SA, of 4-8, cours Michelet-La Défense10-F-92800 Puteaux-France.

[0034] Other powder constituents which may be added to the mixtureinclude a wetting agent such as but not limited to tin, lead, bismuth,antimony, indium or cadmium.

[0035] A homogeneous green composite of the powders having a desiredshape is formed either by deposition in a mould or by using any rapidprototyping technique, such as those described above. A resin bondedpreform is formed by exposing the green composite to a suitable cureinitiator, such as heat or ultra-violet light. This resin bonded preformhas a density of approximately about 50% to about 70% of the theoreticaldensity for the aluminum alloy and structurally has an interconnectingnetwork of pores extending through the preform.

[0036] The binder is next removed, as illustrated in FIG. 1 by numeral14, such as by thermal decomposition, by heating to a temperature in therange of from about 300° C. to about 500° C. with a sufficiently lowheat up rate to avoid the formation of high pressure vapor pockets.Removal of the polymer binder will temporarily reduce the integralstrength of the part. To provide support, a support powder that will notbond to the part under the processing conditions surrounds the preform.Suitable support powders include ceramics, such as alumina, siliconcarbide and boron nitride, mixed with an oxygen scavenger, such asmagnesium. As noted above, inclusion of an oxygen scavenger in thesupport powder may be sufficiently effective to remove the need toinclude an oxygen scavenger in the mixture of powders forming the greencomposite.

[0037] The oxygen scavenger is present in an amount of from about 0.1%to about 10%, by volume, of the support powder, and more preferably, ispresent in an amount of from about 0.5% to about 5%, by volume. Othermetal powders that may be mixed with the ceramic support powder aretitanium, zirconium, lithium, beryllium, calcium, cerium, lanthanum,neodynium, praesodinium, samarium, thorium, uranium, or misch metal andmixtures thereof, either in combination with magnesium or as asubstitute for the magnesium.

[0038] Once the binder has been removed, the temperature is increased toa temperature, effective to promote the formation of aluminum nitride atlow oxygen partial pressures, but not high enough to melt theinfiltrant. An aluminum nitride skeleton 36, seen in FIGS. 5 and 6,forms on the surface of the aluminum-base alloy powders. The aluminumnitride skeleton 36 is rigid and significantly increases the strength ofthe composite. However, because the skeleton is also rigid, anexcessively thick skeleton is not desirable due to the resultantdecreased ductility. As a result, polymer binders having lowerprocessing temperatures are preferred for enhanced ductility. Onesuitable thermal profile is about 2 hours at about 540° C. in a nitrogenatmosphere. Since the rigid skeleton provides dimensional stability, itshould not be attacked by the liquid infiltrant.

[0039] Alloying additions also affect the growth of the nitrideskeleton. The nitride formation rate is highest for pure aluminum andlower for aluminum containing additions of silicon and magnesium,referred to as aluminum alloys of the 6xxx series, where x is between 0and 9. Additions of magnesium absent an inclusion of silicon, referredto as aluminum alloys of the 5xxx series, do not appear to significantlyinhibit the nitride formation rate.

[0040] In addition to aluminum alloy 6061, the following aluminum alloyshave been shown to reduce the rate of nitride formation and are examplesof the preferred first aluminum-base alloy: 6063, nominal composition byweight, Al-0.7% Mg-0.4% Si; 6082, nominal composition by weight Al-0.9%Mg-1.0% Si-0.7% Mn; 6106, nominal composition by weight Al-0.6% Mg-0.45%Si-0.25% Cu and 6351 nominal composition by weight Al-0.6% Mg-1.0%Si-0.6% Mn.

[0041] The infiltrant must melt at a temperature higher than thatrequired for skeleton formation. The infiltrant must melt at atemperature below the melting temperature of the powder mixture. Inaddition, the infiltrant must have sufficient fluidity and asufficiently low viscosity to flow through the interconnected pores ofthe composite. In addition, the contact angle between a bead of theinfiltrant and the skeleton must be sufficiently low to support goodwettability. A contact angle of greater than 90° is typically viewed asnon-wetting while a contact angle of less than 90° is viewed as wetting;the closer to 0° contact angle, the more effective the infiltration.Further considerations are the solubility of the aluminum alloy powderin the liquid infiltrant and the phase diagram of the combination ofaluminum alloy powder and infiltrant. A large number of phases or anumber of transient phases is not desirable, since that could lead toinhomogeneity in the solidified composite.

[0042] Suitable alloys for the infiltrant are eutectic or near eutecticaluminum based alloys. By near eutectic it is meant within about 5% ofthe eutectic, for example the binary aluminum copper eutectic is about33%, by weight, copper, the near eutectic is about 28% to about 33%copper. The infiltrant may be an aluminum based alloy further containingone or more of the following: copper, magnesium, silicon, zinc,titanium, zirconium, iron, silver, lead, tin, bismuth, antimony,strontium, sodium and nickel. In addition to aluminum-base alloys,aluminum with up to about 53% by weight copper alloy is also acceptable.

[0043] As a non-exclusive list, the following alloys are useful as theinfiltrant. All compositions are specified in weight percent. Eachcomposition may contain other, unspecified elements in amount that doesnot materially affect the infiltration properties described above.Silicon  8%-18% Magnesium 3%-7% Aluminum balance. Nominal (Al—13.8%Si—4.7% Mg) melting temperature of 557° C. Copper 28%-38% Aluminumbalance. Nominal (Al—33% Cu) melting temperature of 548.2° C. Silicon 8%-12% Zinc  8%-12% Nickel 3%-8% Aluminum balance. Nominal (Al—10.5%Si—10% Zn—5.5% Ni) melting temperature of 549° C. Silicon  8%-18%Aluminum balance. Nominal (Al—12% Si) melting temperature of 577 ±1° C.

[0044] Once at the infiltration temperature, generally about 10° C.above the melting temperature of the infiltrant, the part is held attemperature for a time effective for complete infiltration, asillustrated in FIG. 1 by numeral 16, of molten infiltrant into thepreform, on the order of about 1 to about 15 hours, and preferably fromabout 2 hours to about 10 hours. At which time the part is cooled,typically at a rate of from about 1° C. per minute to about 5° C. perminute, and nominally 2° C./minute, to solidify, as illustrated in FIG.1 by numeral 18.

[0045] Following solidification, the strength of the part may beincreased by heat treating the infiltrated part. One suitable heattreatment is to heat to from about 500° C. to about 550° C. for fromabout 1 to about 24 hours followed by a water quench. Additionalstrength is achieved through age hardening, either at room temperature(natural aging) or at elevated temperatures, typically at about 100° C.to about 200° C., for a time effective to promote full hardening.

[0046] Other post-solidification treatments may include hot isostaticpressing to close residual porosity and polishing or sand blasting toprovide a smooth finish to the part.

[0047] The mechanism by which the Applicants successfully spontaneouslyinfiltrated an aluminum alloy with a different aluminum alloy isbelieved to be the following. This represents Applicants bestunderstanding of the process as of the filing of the patent application.With reference to FIG. 2, a particle of aluminum alloy powder 20 has ametallic core 22, such as, by weight, nominally Al-1% Mg-0.6% Si-0.25%Cu-0.25% for aluminum alloy 6061. Surrounding the core 22 is a thin,chemically and thermally stable, alumina film 24. With reference to FIG.3, a blended mixture of powders 26 is formed. The mixture 26 includesaluminum or aluminum alloy particles 20 (the alumina film is present,but sufficiently thin not to be illustrated in FIG. 3), oxygen scavengerparticles 28, such as magnesium, and a polymer binder 30, such asnylon-12. As nominal quantities, there is about 2%, by weight, of theoxygen scavenger and about 10% by volume of the binder with the balancealuminum alloy particles.

[0048] With reference to FIG. 4, the blend of powders of FIG. 3 isformed into a desired near net shape, such as by rapid prototyping andoptionally surrounded by a support layer, such as a mixture of aluminaand magnesium powders (not shown). A desired infiltrant 32, such as, byweight, nominally Al-13.8% Si-4.7% Mg, is placed in contact with theblend of powders. The assembly 34 is then heated in an inert atmosphere,preferably nitrogen containing and more preferably, substantially onlynitrogen to a temperature effective to melt the polymer binder 30,without melting any of the metallic components (aluminum alloy powder20, oxygen scavenger 28 and infiltrant 32). For a nylon-12 binder, thistemperature is in the range from about 150° C. to about 300° C.

[0049] With reference to FIG. 5, as the blend of powders of FIG. 3 isfurther heated, such as through the temperature range of from about 300°C. to about 540° C. in nitrogen, the polymer binder 30 begins todecompose. If the polymer binder 30 is nylon-12, the binder decomposesto a carbonaceous residue, ε-Caprolactam (C₆H₁₁NO) and gaseous fixednitrogen species such as HCN, N₂O and NH₃. Gaseous carbon species suchas CO and CO₂ are also formed.

[0050] While the assembly may be moved to different ovens to achieve thedesired thermal exposures, it is preferred that the assembly remain in asingle atmosphere controlled oven programmed with temperatures and timeperiods sufficient to perform each process step in series.

[0051] With reference to FIG. 5, after the removal of the binder, thepart is held at a temperature between the temperatures at which thealuminum nitride compound forms and the temperature at whichinfiltration occurs. By applying an isothermal hold in this temperatureband, and providing the oxygen content is sufficiently low, partialconversion of the aluminum to an aluminum nitride compound occurs.Growth of the aluminum nitride compound results in the formation of arigid skeleton 36. The hold time should be such as to allow sufficientbut not excessive formation of this skeleton 36. Typically, a hold timeof about 2 hours at about 540° C. is used. Once skeleton 36 has formed,the temperature is increased to above that at which the infiltrantbecomes molten to allow spontaneous or pressureless infiltration of thepart. The part is held at the infiltration temperature sufficiently longto ensure full penetration of the liquid, typically about 2 to about 4hours, as illustrated in FIG. 6.

[0052] The above invention will become more apparent from the Examplesthat follow.

EXAMPLES Example 1

[0053] A green composite was made by selective laser sintering of apowder mixture containing 6061 powder, 2 wt % Mg and 10 vol % nylonbinder using each of the nylon binders previously recited as beingcommercially available from Atofina S.A. An infiltrant with acomposition, by weight, of Al-13.8Si-4.9Mg was placed in contact withthe preform. The amount of the infiltrant was sufficient to just fillthe pore volume. The assembly was then placed inside a crucible andcovered with a support powder consisting of alumina containing 1 vol %Mg powder. The crucible was then placed inside a nitrogen-atmospherefurnace and heated at approximately 90° C. per hour to a temperature of540° C. and held for a period of 2 hours to allow the skeleton to form.The furnace temperature was then increased at the same rate to 570° C.and held for 4 hours to allow spontaneous infiltration of the wholepreform. The parts were then furnace cooled until the temperature wasbelow 200° C. and then removed from the furnace and air-cooled. Theparts were removed from the support powder and sand blasted. The densityof each part was close to the theoretical density for the aluminum-basealloy.

[0054] Similarly successful infiltrations were obtained by the processesrecited in Examples 2 through 7 that follow.

Example 2

[0055] An alloy was made and processed as per Example 1 but with aninfiltrant composition of Al-33 wt % Cu.

Example 3

[0056] An alloy was made and processed as per Example 1, but with aninfiltrant composition of Al-10.5Si-10Zn-5.5Ni.

Example 4

[0057] An alloy was made and processed as per Example 1, but with aninfiltrant composition of Al-12Si and an infiltration temperature of590° C.

Example 5

[0058] An alloy was made and processed as per Example 1, but the initialpowder mixture consisted of 6061 powder and 10 vol % nylon binder.

Example 6

[0059] An alloy was made and processed as per Example 1, but the initialpowder mixture consisted of aluminum powder, 2 wt % Mg and 10 vol %nylon binder.

Example 7

[0060] A green body consisting of a powder mixture containing 6061powder, 2 wt % Mg and 10 vol % nylon binder using each of the nylonbinders previously recited as being commercially available from AtofinaS.A. was made by placing the powder mixture in a mould and heating thisto a temperature above the melting point of the nylon. On cooling, theresin-body green body was extracted from the mould and processed as perExample 1.

[0061] It should be noted that the present process is applicable toother materials and compositions, and one skilled in the art willunderstand that the alloys, blend percentages, particle sizes, andtemperatures described herein are presented as examples and notlimitations of the present invention.

[0062] One or more embodiments of the present invention have beendescribed. Nevertheless, it will be understood that variousmodifications may be made without departing from the spirit and scope ofthe invention. Accordingly, other embodiments are within the scope ofthe following claims.

What is claimed is:
 1. A method for the manufacture of athree-dimensional object, comprising the steps of: a) forming a mixturethat contains a binder and at least one of aluminum or a firstaluminum-base alloy into a green composite; b) removing said binder fromsaid green composite forming a porous preform structure; and c)infiltrating said porous preform structure with an infiltrant that is amolten second aluminum base alloy to form said three-dimensional objectwith near theoretical density.
 2. The method of claim 1 wherein saidfirst aluminum base alloy is selected to be an alloy with copper,magnesium, silicon, zinc, titanium, chromium, zirconium, nickel, iron,manganese, silver, and mixtures thereof.
 3. The method of claim 2wherein said first aluminum base alloy is alloyed with silicon.
 4. Themethod of claim 3 wherein said first aluminum base alloy is alloyed witha combination of silicon and magnesium.
 5. The method of claim 4 whereinsaid first aluminum base alloy is selected to be, by weight, about 0.4%to about 0.8% silicon, about 0.15% to about 0.40% copper, about 0.8% toabout 1.2% magnesium, about 0.04% to about 0.35% chromium and thebalance is aluminum and unavoidable impurities.
 6. The method of claim 2wherein said binder is selected to be a polymer that substantiallydecomposes to gases at a temperature of between about 300° C. and about500° C. in a nitrogen-base atmosphere.
 7. The method of claim 6 whereinsaid binder is selected to be a nylon.
 8. The method of claim 2including an addition of an oxygen scavenger to said mixture.
 9. Themethod of claim 8 wherein said oxygen scavenger is selected to bemagnesium.
 10. The method of claim 1 wherein said infiltrant is selectedto be a eutectic or near eutectic of aluminum with copper, magnesium,silicon, zinc, titanium, zirconium, iron, silver, lead, tin, bismuth,antimony, strontium, sodium, nickel and mixtures thereof.
 11. The methodof claim 10 wherein said infiltrant is selected to include silicon andmagnesium.
 12. The method of claim 11 wherein said infiltrant isselected to have a nominal composition, by weight, of 13.8% silicon,4.7% magnesium and the balance is aluminum and inevitable impurities.13. The method of claim 11 wherein said infiltrant is selected to have anominal composition, by weight, of less than about 53% copper and thebalance is aluminum and inevitable impurities.
 14. The method of claim 1wherein step (b) is at a temperature of between about 300° C. and about500° C., step (c) is at a temperature of from about 540° C. to atemperature in excess of about 540° C., but less than the melting orsolidus temperature of the first aluminum alloy.
 15. The method of claim14 wherein steps (b)-(c) are in a single oven programmed withtemperatures and times effective for each step and said steps areperformed in a nitrogen-base atmosphere.
 16. The method of claim 14wherein prior to step (b), said porous preform structure is surroundedwith a porous support structure, said porous support structure selectedto include both a ceramic and an oxygen scavenger.
 17. The method ofclaim 16 in which said oxygen scavenger is selected to be magnesium. 18.A method for the manufacture of a three-dimensional object having adesired shape, comprising the steps of: a) forming a mixture thatcontains a binder and at least one of aluminum or a first aluminum-basealloy into a green composite having said desired shape; b) removing saidbinder from said green composite by a process effective to maintain saiddesired shape as a porous preform structure; c) converting a portion ofsaid aluminum to aluminum nitride thereby transforming said greencomposite to a rigid skeleton of said desired shape with said porouspreform structure; and d) infiltrating said porous preform structurewith an infiltrant that is a molten second aluminum-base alloy; to formsaid three-dimensional object with a near theoretical density.
 19. Themethod of claim 18 wherein said first aluminum base alloy is selected tobe an alloy with copper, magnesium, silicon, zinc, titanium, chromium,zirconium, nickel, iron, manganese, silver, and mixtures thereof. 20.The method of claim 19 wherein said first aluminum base alloy is alloyedwith silicon and magnesium.
 21. The method of claim 18 wherein saidbinder is selected to be a polymer that substantially decomposes togases at a temperature of between about 300° C. and about 500° C. in anitrogen-base atmosphere.
 22. The method of claim 21 wherein said binderis selected to be a nylon.
 23. The method of claim 18 including anaddition of an oxygen scavenger to said mixture.
 24. The method of claim23 wherein said oxygen scavenger is selected to be magnesium.
 25. Themethod of claim 23 including the step of forming a nitride skeletonwithin said porous preform structure by exposure to nitrogen at lowoxygen partial pressure.
 26. The method of claim 18 wherein saidinfiltrant is selected to be a eutectic or near eutectic of aluminumwith copper, magnesium, silicon, zinc, titanium, zirconium, iron,silver, lead, tin, bismuth, antimony, strontium, sodium, nickel andmixtures thereof.
 27. The method of claim 26 wherein said infiltrant isselected to include silicon and magnesium.
 28. The method of claim 27wherein said infiltrant is selected to have a nominal composition, byweight, of 13.8% silicon, 4.7% magnesium and the balance is aluminum andinevitable impurities.
 29. The method of claim 27 wherein saidinfiltrant is selected to have a nominal composition, by weight, of lessthan about 53% copper and the balance is aluminum and inevitableimpurities.
 30. The method of claim 18 wherein step (b) is at atemperature of between about 300° C. and about 500° C., step (c) is at atemperature of from about 500° C. to about 570° C. and step (d) is at atemperature of from about 540° C. to a temperature in excess of about540° C., but less than the melting or solidus temperature of the firstaluminum alloy.
 31. The method of claim 30 wherein steps (b)-(d) are ina single oven programmed with temperatures and times effective for eachstep and said steps are performed in a nitrogen-base atmosphere.
 32. Themethod of claim 30 wherein prior to step (b), said porous preform issurrounded with a porous support structure, said porous supportstructure selected to include both a ceramic and an oxygen scavenger.33. The method of claim 32 in which said oxygen scavenger is selected tobe magnesium.
 34. The method of claim 30 wherein said desired shape isformed by computer aided rapid prototyping.
 35. The method of claim 34wherein said desired shape is formed by selective laser sintering. 36.The method of claim 18 wherein subsequent to step (d), said threedimensional object is further densified by hot isostatic pressing. 37.The method of claim 18 wherein subsequent to step (d), said threedimension object is smooth finished.
 38. The method of claim 18 whereinsubsequent to step (d), said three dimension object is heat treated. 39.A method for the manufacture of a three-dimensional object, comprisingthe steps of: a) forming a mixture that contains a binder and at leastone of aluminum or a first aluminum-base alloy into a green composite;b) removing said binder from said green composite forming a porouspreform structure; c) transforming a portion of the aluminum and/orfirst aluminum base alloy into an aluminum nitride compound by reactionwith a nitrogen source to form a rigid skeleton; and d) infiltratingsaid porous preform structure with an infiltrant that is a molten secondaluminum base alloy to form said three-dimensional object with neartheoretical density.
 40. The method of claim 39 wherein said firstaluminum base alloy is selected to be an alloy with copper, magnesium,silicon, zinc, titanium, chromium, zirconium, nickel, iron, manganese,silver, and mixtures thereof.
 41. The method of claim 40 wherein saidfirst aluminum base alloy is alloyed with silicon and magnesium.
 42. Themethod of claim 39 wherein said binder is selected to be a polymer thatsubstantially decomposes to gases at a temperature of between about 300°C. and about 500° C. in a nitrogen-base atmosphere.
 43. The method ofclaim 42 wherein said binder is selected to be a nylon.
 44. The methodof claim 39 including an addition of an oxygen scavenger to saidmixture.
 45. The method of claim 44 wherein said oxygen scavenger isselected to be magnesium.
 46. The method of claim 44 including the stepof forming a nitride skeleton within said porous preform by exposure tonitrogen at low oxygen partial pressure.
 47. The method of claim 39wherein said infiltrant is selected to be a eutectic or near eutectic ofaluminum with copper, magnesium, silicon, zinc, titanium, zirconium,iron, silver, lead, tin, bismuth, antimony, strontium, sodium, nickeland mixtures thereof.
 48. The method of claim 47 wherein said infiltrantis selected to include silicon and magnesium.
 49. The method of claim 48wherein said infiltrant is selected to have a nominal composition, byweight, of 13.8% silicon, 4.7% magnesium and the balance is aluminum andinevitable impurities.
 50. The method of claim 48 wherein saidinfiltrant is selected to have a nominal composition, by weight, of lessthan about 53% copper and the balance is aluminum and inevitableimpurities.
 51. The method of claim 39 wherein step (b) is at atemperature of between about 300° C. and about 500° C., step (c) is at atemperature of from about 500° C. to about 570° C. and step (d) is at atemperature of from about 540° C. to a temperature in excess of about540° C., but less than the melting or solidus temperature of the firstaluminum alloy.
 52. The method of claim 51 wherein steps (b)-(d) are ina single oven programmed with temperatures and times effective for eachstep and said steps are performed in a nitrogen-base atmosphere.
 53. Themethod of claim 51 wherein prior to step (b), said porous preformstructure is surrounded with a porous support structure, said poroussupport structure selected to include both a ceramic and an oxygenscavenger.
 54. The method of claim 53 in which said oxygen scavenger isselected to be magnesium.
 55. The method of claim 39 wherien saiddesired shape is formed by computer aided rapid prototyping.
 56. Themethod of claim 55 wherein said desired shape is formed by selectivelaser sintering.
 57. The method of claim 39 wherein subsequent to step(d), said three dimensional object is further densified by hot isostaticpressing.
 58. The method of claim 39 wherein subsequent to step (d),said three dimensional object is smooth finished.
 59. The method ofclaim 39 wherein subsequent to step (d), said three dimensional objectis heat treated.